System and Method to Control Pre-Ignition in an Internal Combustion Engine
An engine system and method are disclosed for controlling pre-ignition of an alcohol fuel. In one embodiment, the fuel injection timing is adjusted to cause the fuel to avoid combustion chamber surfaces. In another embodiment, the fuel injection timing is adjusted to spray the fuel directly onto the piston surface to cool the piston. Also disclosed is a cylinder cleaning cycle in which engine knock is purposely caused for one to hundreds of engine cycles by adjusting the fuel content away from alcohol toward gasoline. Further measures to cause knock which are disclosed: adjusting spark timing, intake boost, exhaust gas fraction in the cylinder, cam timing, and transmission gear ratio.
The present invention relates to controlling pre-ignition in internal combustion engines.
BACKGROUND OF THE INVENTIONAlcohol fuels are known to have a high octane number, which inhibits autoignition (also known as knock; knock is self ignition of end gases ahead of the flame front occurring after spark firing) in spark-ignited internal combustion engines. This allows an internal combustion engine to be operated at a higher compression ratio and/or a higher level of pressure charging in the intake system. However, alcohol fuels are prone to pre-ignition, which is a combustion phenomenon occurring prior to spark plug firing. It is believed to be a surface phenomenon where the fuel comes in contact with a hot spot in the combustion chamber, such as the spark plug tip, a bit of carbon deposit, the piston top, and exhaust valve, and initiates a flame front. This can lead to damage of the engine because it can become a runaway problem. That is, when pre-ignition first occurs, the early combustion leads to very high in-cylinder temperatures and high heat transfer to combustion chamber surfaces. Then, in succeeding cycles, pre-ignition is even more likely and happens earlier in the compression stroke making the temperatures even higher. If left unchecked, high temperatures can lead to engine parts melting and complete failure of the engine. It is known in the art to undertake measures to mitigate pre-ignition.
SUMMARY OF THE INVENTIONThe inventor of the present invention has recognized that spark-ignited engine with direct injection, i.e., those in which fuel is sprayed into the cylinder directly, have more control over the injection of the fuel into the cylinder than conventional port fuel injected engines. A method is disclosed in which the injection timing of the direct injector is adjusted to avoid pre-ignition. This adjustment can be based on detection of pre-ignition by a flywheel speed sensor, an accelerometer coupled to the engine, an ionization sensor coupled to the cylinder, a pressure sensor coupled to the engine, or other sensor. Alternatively, pre-ignition is determined open loop, meaning that the engine conditions at which pre-ignition are determined experimentally. When such conditions are accessed by the engine, the engine control unit adjusts the fuel injection timing to avoid the pre-ignition. Beyond engine operating conditions such as speed, torque, engine coolant temperature, intake air temperature, and exhaust gas recirculation (EGR) fraction, other factors affecting the propensity to pre-ignite are: fuel properties and humidity. Fuel properties comprise, for example, the fraction of alcohol in the fuel, the type of alcohol, or alcohols, and the properties of the diluent fuel, e.g., gasoline.
The inventor of the present invention recognizes two strategies to mitigate pre-ignition. In one method, fuel is injected into the cylinder to avoid contact with the surface as much as possible. This is accomplished by injecting the fuel when the piston is at its farthest position from the fuel injector, i.e., BDC. As injection occurs over a range of piston positions, the fuel injection begins prior to the piston reaching BDC and concludes after the piston passes BDC, approximately centering the injection duration at BDC. This provides the least opportunity for the fuel to hit the piston's surface as well as bouncing off the piston top and spraying onto other hot combustion chamber surfaces such as exhaust valves or spark plug tips. Further, the fuel is predominantly in contact with the air, thus, absorbing the energy for its phase change from liquid to gaseous from the air. Cooling of the charge provides two advantages: reducing the density of the air in the cylinder allowing more air to be inducted and thus more power produced in the cylinder; and prevention of endgas autoignition or knock. In a second method, fuel is intentionally injected onto the piston top. The evaporation of the fuel from the piston top provides cooling of that surface and mitigates pre-ignition. To spray onto the piston, fuel is injected early on the intake stroke, a downward stroke of the piston. Alternatively, fuel is injected late on the compression stroke, an upward stroke of the piston. Injecting during the intake stroke allows sufficient time for air-fuel mixing; whereas, mixing time is limited when injection occurs during compression.
The present invention can be used in a dual-fuel engine in one fuel is predominantly alcohol and the other fuel is predominantly gasoline. Preferably, the alcohol fuel is injected into the cylinder directly and the gasoline fuel is injected into the intake port. Because the alcohol fuel has a higher resistance to knock, it is used either exclusively, or predominantly, when the operating condition has a high propensity to knock. However, a problem arises when the alcohol fuel is pre-igniting. However, if the gasoline fuel is used, knock occurs. The inventor of the present invention recognizes that one to possibly several hundred cycles of knock is not damaging to the engine, with the only drawback being an objectionable noise. Thus, it is disclosed that in such a situation, either all cylinders, or preferably only the cylinder or cylinders that are suffering from pre-ignition be caused to knock. It is known that knock causes a high frequency pressure wave to develop in the cylinder and can act to remove cylinder deposits which may be causing the pre-ignition. By performing such an operation in only the cylinders that suffer from pre-ignition, the objectionable knocking sound is minimized. According to a further aspect of the invention, the purposeful knocking condition is indicated to the operator of the vehicle as a dashboard light, text display, sound, or any other known methods of driver information. Because knock is commonly associated to most vehicle operators as an engine problem, an operator indicator that the engine is undergoing a cleaning cycle reassures the operator that the knocking sound is intended and not an indication that action be taken.
The above advantages, other advantages, and features of the present invention will be readily apparent from the following detailed description of the preferred embodiments when taken in connection with the accompanying drawings.
The advantages described herein will be more fully understood by reading an example of an embodiment in which the invention is used to advantage, referred to herein as the Detailed Description, with reference to the drawings wherein:
A 4-cylinder internal combustion engine 10 is shown, by way of example, in
Continuing to refer to HG. 1, electronic control unit (ECU) 40 is provided to control engine 10. ECU 40 has a microprocessor 46, called a central processing unit (CPU), in communication with memory management unit (MMU) 48. MMU 48 controls the movement of data among the various computer readable storage media and communicates data to and from CPU 46. The computer readable storage media preferably include volatile and nonvolatile storage in read-only memory (ROM) 50, random-access memory (RAM) 54, and keep-alive memory (KAM) 52, for example. KAM 52 may be used to store various operating variables while CPU 46 is powered down. The computer-readable storage media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by CPU 46 in controlling the engine or vehicle into which the engine is mounted. The computer-readable storage media may also include floppy disks, CD-ROMs, hard disks, and the like. CPU 46 communicates with various sensors and actuators via an input/output (I/O) interface 44. Examples of items that are actuated under control by CPU 46, through I/O interface 44, are fuel injection timing, fuel injection rate, fuel injection duration, throttle valve 32 position, spark plug 26 timing, EGR valve 18. Various other sensors 42 (such as a humidity sensor, an engine block accelerometer, an ionization sensor, as examples) and specific sensors (engine speed sensor 22, in-line torque sensor 25, cylinder pressure transducer sensor 30, engine coolant sensor 38, manifold absolute pressure sensor 31, exhaust gas component sensor 24, air temperature sensor 34, and mass airflow sensor 36) communicate input through I/O interface 44 and may indicate engine rotational speed, vehicle speed, coolant temperature, manifold pressure, pedal position, cylinder pressure, throttle valve position, air temperature, exhaust temperature, exhaust stoichiometry, exhaust component concentration, and air flow. Some ECU 40 architectures do not contain MMU 48. If no MMU 48 is employed, CPU 46 manages data and connects directly to ROM 50, RAM 54, and KAM 52. Of course, the present invention could utilize more than one CPU 46 to provide engine control and ECU 60 may contain multiple ROM 50, RAM 54, and KAM 52 coupled to MMU 48 or CPU 46 depending upon the particular application.
Referring to
Referring to
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Determination of which cylinder or cylinders pre-igniting, as shown in block 204 of
According to an aspect of the present invention, the dual-fuel engine uses a predominantly gasoline fuel which may contain up to 15% alcohol and a predominantly alcohol fuel which may contain up to 25% gasoline, herein referred to gasoline fuel and alcohol fuel, with the understanding that both fuels may be blends. The alcohol comprises any alcohol: methanol, ethanol, propanol, etc. or blend thereof.
While several modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize alternative designs and embodiments for practicing the invention. The above-described embodiments are intended to be illustrative of the invention, which may be modified within the scope of the following claims.
Claims
1-27. (canceled)
28. A method for operating an internal combustion engine, comprising:
- detecting pre-ignition; and
- adjusting injection timing of a direct injector such that a majority of fuel is injected when the piston is at its furthest position from the injector, said direct injector being coupled to a cylinder of the engine and sprays fuel directly into said cylinder.
29. The method of claim 28 wherein said injection occurs when said piston is near bottom dead center prior to the compression stroke.
30. The method of claim 28 wherein said detection is based on a signal from a flywheel speed sensor.
31. The method of claim 28 wherein said detection is based on one of an exhaust gas temperature sensor, an ionization sensor, and a pressure sensor.
32. A method for operating an internal combustion engine, comprising:
- detecting pre-ignition; and
- adjusting injection timing of a direct injector so that fuel sprays onto the piston top to cool the piston, said direct injector being coupled to a cylinder of the engine and sprays fuel directly into said cylinder.
33. The method of claim 32 wherein said injection timing is approximately centered around the time when the piston is at top dead center during valve overlap.
34. The method of claim 32 wherein said detection is based on a signal from a flywheel speed sensor.
35. The engine of claim 32 wherein occurrence of pre-ignition is estimated based on engine operating conditions.
36. The engine of claim 32 wherein detection of pre-ignition is based on fuel characteristics.
37. The method of claim 32 wherein said cylinders are supplied fuel with greater than 75% alcohol content by said direct injector and gasoline fuel by a port injector wherein said gasoline may contain up to 15% alcohol.
38. The method of claim 37, further comprising: increasing a proportion of fuel energy supplied by said port injector for at least one knocking combustion event.
39. The method of claim 38 wherein said increasing of fuel is accomplished only in cylinders in which pre-ignition is occurring.
40. The method of claim 39, further comprising: increasing a proportion of fuel energy supplied by said direct injector after said at least one knocking combustion event.
41. The method of claim 40, further comprising: providing an indication to the operator of the engine that the engine is performing a cleaning cycle.
42. The method of claim 41, further comprising: decreasing a proportion of fuel energy supplied by said direct injector, said total energy supplied based on providing an operator desired torque.
43. An internal combustion engine system, comprising:
- an engine cylinder;
- a direct injector coupled to said cylinder; and
- an electronic control unit electronically coupled to the engine and said direct injector, said electronic control unit determining whether pre-ignition is occurring and in response to pre-ignition adjusting injection timing of said injector toward when a piston in said cylinder is nearest said injector to cause fuel from said fuel injector to impact a top of said piston.
44. The engine of claim 43, further comprising: a port injector coupled to an engine intake, said engine intake communicating with said cylinder via an intake valve wherein said electronic control unit is electronically coupled to said port injector, said direct injector supplying fuel with greater than 75% alcohol content and said port injector supply fuel with less than 15% alcohol content, said electronic control unit increasing an amount of fuel supplied by said port injector and decreasing an amount of fuel supplied by said direct injector in response to pre-ignition in said cylinder.
45. The engine of claim 43, further comprising: a flywheel sensor electronically coupled to said electronic control unit basing said determination of preignition on a signal from said flywheel sensor.
46. The engine of claim 44 wherein said increasing of fuel supplied by said port injector is accomplished only in cylinders in which pre-ignition is occurring.
Type: Application
Filed: Jan 17, 2007
Publication Date: Apr 23, 2009
Patent Grant number: 7685996
Inventor: Diana D. Brehob (Dearborn, MI)
Application Number: 11/624,892
International Classification: F02P 5/04 (20060101);